ZONESUN ZS-FAL180V14 GMP Sterile Vial liquids Filling and Capping Production Line

Description

The ZONESUN ZS-FAL180V14 is a GMP-compliant, fully automated vial filling production line purpose-built for sterile injectable products, vaccines, veterinary drugs, and other aseptic liquids. It consolidates water purification, liquid mixing, vial feeding, precision filling, rubber stopper insertion, aluminum cap crimping, and self-adhesive labeling into a single continuous system — eliminating inter-station contamination risks and reducing operator intervention.

Equipped with a Class 100 laminar flow hood, food-grade SUS304 stainless steel product-contact parts, and servo-controlled ceramic piston pumps achieving ±0.02 ml accuracy at 30 ml fill volume, the ZS-FAL180V14 delivers pharmaceutical-grade consistency at 3,600–4,800 vials/hour. Filling range, tank capacity, and head configuration are fully customizable to accommodate diverse vial formats and production scales.

Parameter

Type Water Purification System

• Product Model ZS-WP500L
  
• Power Supply 220 V, 50 HZ (Customizable)
  
• Purified Water Conductivity 1–10 μS/cm (25°C)
  
• Production Capacity 500 L/H
  
• Desalination Rate 95%
  
• Recovery Rate 50-60%
  
• Machine Size About 1900 × 650 × 1650 mm (L × W × H)
  
• Package Size About 1960 × 830 × 1710 mm (L × W × H)
  
• Package Weight About 488 kg

Type Water Purification System

• Product Model ZS-WP500L
  
• Power Supply 220 V, 50 HZ (Customizable)
  
• Purified Water Conductivity 1–10 μS/cm (25°C)
  
• Production Capacity 500 L/H
  
• Desalination Rate 95%
  
• Recovery Rate 50-60%
  
• Machine Size About 1900 × 650 × 1650 mm (L × W × H)
  
• Package Size About 1960 × 830 × 1710 mm (L × W × H)
  
• Package Weight About 488 kg

Type Vial Filling Crimping Machine

• Machine Model ZS-AFC39F
  
• Voltage AC 110/220 V 50-60 Hz
  
• Power <3000 W/h
  
• Working Speed About 60-80 Bottles/min (Depending on filling range)
  
• Filling Pump Ceramic Plunger Pump
  
• Filling Nozzle Quantity 2
  
• Filling Range 30 ml (Customizable)
  
• Filling Accuracy ±3 %
  
• Machine Size About 2660*1700*2150 mm (L*W*H)
  
• Package Size About 1180*690*790 mm (Vibratory Bowl Sorter)
  
• About 2890*1730*2340 mm (Main Machine)
  
• Package Weight About 135 kg (Vibratory Bowl Sorter) + 1565 kg (Main Machine)

Type Labeling Machine

• Machine Model ZS-TB821
  
• Voltage 220V/110V 50-60Hz
  
• Power 570 W
  
• Labeling Accuracy ±1.0 mm
  
• Labeling Speed About 40-120 bottles/min (Depending on label size)
  
• Applicable Product Size φ25-φ120 mm (Round bottle)
  
• Label Size (W)20-300 mm * (H)20-95 mm
  
• Label Roll ID φ76 mm
  
• Label Roll OD φ300 mm
  
• Machine Size About 2040*1180*1370 mm (L*W*H)
  
• Package Size About 2200*1170*1600 mm (L*W*H)
  
• Package Weight About 330 kg

Key Features

• End-to-End GMP Integration: Combines water purification, mixing, vial feeding, filling, stoppering, crimping, and labeling in one validated automated line, minimizing contamination risk and operator touchpoints.
• Class 100 Laminar Flow Protection: Built-in laminar flow hood maintains ISO 5 / Class 100 conditions at the filling zone, meeting aseptic processing requirements for injectables and vaccines.
• Servo-Controlled Ceramic Piston Pumps: Delivers ±0.02 ml filling accuracy at 30 ml volume, ensuring dose consistency and reducing product waste across high-volume runs.
• High-Speed Dual-Head Filling: Achieves 3,600–4,800 vials/hour with dual nozzles, supporting large-scale pharmaceutical and veterinary production schedules.
• Food-Grade SUS304 Contact Parts: All product-contact surfaces are food-grade stainless steel, ensuring chemical resistance, easy cleaning, and compliance with pharmaceutical hygiene standards.
• Integrated Water Purification (ZS-WP500L): On-board 500 L/H RO purification system produces 1–10 μS/cm conductivity water, eliminating the need for a separate water treatment facility.
• Precision Self-Adhesive Labeling (ZS-TB821): Inline round-bottle labeling at 40–120 bottles/min with ±1.0 mm accuracy, supporting φ25–φ120 mm vials and a wide label size range.
• Fully Customizable Configuration: Filling range, tank capacity, nozzle count, and voltage (110V/220V, 50/60 Hz) are all configurable to match specific product and facility requirements.

Applications

• Injectable Pharmaceutical Manufacturing: Sterile filling and sealing of small-volume parenterals (SVP), including antibiotics, hormones, and biological injectables in glass or plastic vials.
• Vaccine Production: Aseptic filling of human and veterinary vaccines requiring Class 100 environment, precise dosing, and tamper-evident aluminum cap crimping.
• Veterinary Drug Packaging: High-speed filling and capping of veterinary injectables, multi-dose vials, and animal health liquids with flexible format changeover.
• Ophthalmic & Specialty Liquids: Filling of sterile ophthalmic solutions, diagnostic reagents, and other sensitive liquids requiring contamination-free processing.
• Biotech & Biosimilar Filling: Suitable for contract development and manufacturing organizations (CDMOs) handling biologics, biosimilars, and cell-culture-derived products.
• Contract Pharmaceutical Packaging (CMO): Flexible multi-SKU vial filling for contract manufacturers requiring rapid changeover between vial sizes, fill volumes, and label formats.
• Export & Regulated Markets: Line configuration and GMP documentation support compliance with WHO, EU GMP, FDA, and other international pharmaceutical manufacturing regulations.